https://cdn.mtdcnc.global/cnc/wp-content/uploads/2020/07/07101208/32-Fig-1-CBN-grade-IB20H-insert-for-hard-part-turning-_-1-640x360.jpg
    Tooling

    Grade upgrade

    • By Iscar
    • July 16, 2020
    • 4 minute read

    Building a house begins with the foundation, its longevity depends on the foundation strength. With cutting tools, this foundation is the material. There are various cutting materials such as cemented carbide, PCD, HSS, ceramics and more. Each type contains different grades. Through history, the introduction of each material and its use has led to a significant change in performance. The last century was marked by the progress of material technology and now, we see fewer new solutions. Does this mean development of new tool materials has already peaked and is experiencing stagnation?

    No, it is simply that new developments are deep within the cutting material and are focused on its structure. This can be observed only with the help of scanning electron microscopy (SEM), X-ray diffraction (XRD), electron backscatter diffraction (EBCD), and other sophisticated methods. They cover a tremendously complicated world of coatings that is extremely diverse.

    The most common available cutting material today is cemented carbide, primarily coated. In terms of performance, it represents a balance between efficiency, tool life and cost. Cemented carbide is known also as ‘tungsten carbide’ or simply ‘carbide’. A combination of cemented carbide, coating, and post-coat treatment produces a carbide grade. Only one of these components, the cemented carbide, is an essential element in the grade.

    Cemented carbide comprises hard carbide particles cemented together by binding metal (mainly cobalt). Most cemented carbides integrate wear-resistant coatings. New developments in cemented carbide are concentrated in three directions, carbide production, advanced coating methods and innovative post-coating techniques. Considerable success has been achieved in each direction. This is reflected in the wealth of new products introduced to the market.

    Customers analyse grades using parameters such as productivity, tool life and performance. In upgrading carbide grades, ISCAR is very sensitive to the challenge faced by industry. In this context, ISCAR’s solutions are developed considering the trends of modern metalworking. For example, titanium and superalloy use has increased.

    The growing usage demands technological solutions. The new tools require an appropriate foundation, made of advanced materials to achieve the desired cutting geometry. And for the construction of this foundation, ISCAR offers its new effective ‘bricks’ – upgraded carbide grades developed by metallurgists in the last few years.

    In milling, ISCAR has developed PVD coated IC882 and CVD coated IC5820 grades– two chocolate-color carbide grades for cutting titanium, high-temperature alloys and stainless. An integral component is a post coating treatment that facilitates longer tool life, due to increased resistance to chipping, notch wear, and build-up edge formation. The IC882 grade demonstrates impressive performance when machining conditions are hard, and the advantages of the IC5820 are most fully manifested when applied to milling with pinpointed high-pressure coolant supply.

    The PVD coated carbide grade IC806 was designed especially for turning high-temperature superalloys. As a result of the high mark that the grade received from the manufacturers of aerospace components, ISCAR expanded the application range of IC806 for laydown threading inserts. In addition to cemented carbide, industry consumes other hard cutting materials such as ceramics, diamond and cubic boron nitride (CBN). Their application on difficult-to-cut materials facilitates considerable increases in productivity. In recent years, ISCAR has enriched its cutting material range by introducing several new non-carbide grades, including the SiAlON grades IS25 and IS35 for cutting high-temperature alloys and the CBN grade IB20H for hard part turning.

    At the same time, customer demand is not limited to the effective machining of exotics. Steel is still the main structural material and ISCAR’s last innovation was in the parting and grooving realm – two new PVD coated carbide grades, IC1010 and IC1030. These were utilised in inserts from the TANG-GRIP and DO-GRIP families (Fig. 2). The grades are intended for machining stainless steel and steel. While the hard submicron grade IC1010 is recommended for productive parting and grooving with high cutting speed, the tough IC1030 is more suitable for interrupted cut and unstable machining conditions.

    Upgrading grades is an essential component for tool manufacturers’ success, and innovations should have a strong foundation. This why ISCAR’s motto ‘to be on the upgrade’ guides and inspires new tool material developments.

    https://cdn.mtdcnc.global/cnc/wp-content/uploads/2020/07/07101208/32-Fig-1-CBN-grade-IB20H-insert-for-hard-part-turning-_-1-640x360.jpg

    Grade upgrade

    Building a house begins with the foundation, its longevity depends on the foundation strength. With cutting tools, this foundation is the material. There are various cutting materials such as cemented carbide, PCD, HSS, ceramics and more. Each type contains different grades. Through history, the introduction of each material and its use has led to a significant change in performance. The last century was marked by the progress of material technology and now, we see fewer new solutions. Does this mean development of new tool materials has already peaked and is experiencing stagnation?

    No, it is simply that new developments are deep within the cutting material and are focused on its structure. This can be observed only with the help of scanning electron microscopy (SEM), X-ray diffraction (XRD), electron backscatter diffraction (EBCD), and other sophisticated methods. They cover a tremendously complicated world of coatings that is extremely diverse.

    The most common available cutting material today is cemented carbide, primarily coated. In terms of performance, it represents a balance between efficiency, tool life and cost. Cemented carbide is known also as ‘tungsten carbide’ or simply ‘carbide’. A combination of cemented carbide, coating, and post-coat treatment produces a carbide grade. Only one of these components, the cemented carbide, is an essential element in the grade.

    Cemented carbide comprises hard carbide particles cemented together by binding metal (mainly cobalt). Most cemented carbides integrate wear-resistant coatings. New developments in cemented carbide are concentrated in three directions, carbide production, advanced coating methods and innovative post-coating techniques. Considerable success has been achieved in each direction. This is reflected in the wealth of new products introduced to the market.

    Customers analyse grades using parameters such as productivity, tool life and performance. In upgrading carbide grades, ISCAR is very sensitive to the challenge faced by industry. In this context, ISCAR’s solutions are developed considering the trends of modern metalworking. For example, titanium and superalloy use has increased.

    The growing usage demands technological solutions. The new tools require an appropriate foundation, made of advanced materials to achieve the desired cutting geometry. And for the construction of this foundation, ISCAR offers its new effective ‘bricks’ – upgraded carbide grades developed by metallurgists in the last few years.

    In milling, ISCAR has developed PVD coated IC882 and CVD coated IC5820 grades– two chocolate-color carbide grades for cutting titanium, high-temperature alloys and stainless. An integral component is a post coating treatment that facilitates longer tool life, due to increased resistance to chipping, notch wear, and build-up edge formation. The IC882 grade demonstrates impressive performance when machining conditions are hard, and the advantages of the IC5820 are most fully manifested when applied to milling with pinpointed high-pressure coolant supply.

    The PVD coated carbide grade IC806 was designed especially for turning high-temperature superalloys. As a result of the high mark that the grade received from the manufacturers of aerospace components, ISCAR expanded the application range of IC806 for laydown threading inserts. In addition to cemented carbide, industry consumes other hard cutting materials such as ceramics, diamond and cubic boron nitride (CBN). Their application on difficult-to-cut materials facilitates considerable increases in productivity. In recent years, ISCAR has enriched its cutting material range by introducing several new non-carbide grades, including the SiAlON grades IS25 and IS35 for cutting high-temperature alloys and the CBN grade IB20H for hard part turning.

    At the same time, customer demand is not limited to the effective machining of exotics. Steel is still the main structural material and ISCAR’s last innovation was in the parting and grooving realm – two new PVD coated carbide grades, IC1010 and IC1030. These were utilised in inserts from the TANG-GRIP and DO-GRIP families (Fig. 2). The grades are intended for machining stainless steel and steel. While the hard submicron grade IC1010 is recommended for productive parting and grooving with high cutting speed, the tough IC1030 is more suitable for interrupted cut and unstable machining conditions.

    Upgrading grades is an essential component for tool manufacturers’ success, and innovations should have a strong foundation. This why ISCAR’s motto ‘to be on the upgrade’ guides and inspires new tool material developments.